CN116475305B - Commercial vehicle and light commercial wheel house bracket tube beam and manufacturing method thereof - Google Patents
Commercial vehicle and light commercial wheel house bracket tube beam and manufacturing method thereof Download PDFInfo
- Publication number
- CN116475305B CN116475305B CN202310736009.8A CN202310736009A CN116475305B CN 116475305 B CN116475305 B CN 116475305B CN 202310736009 A CN202310736009 A CN 202310736009A CN 116475305 B CN116475305 B CN 116475305B
- Authority
- CN
- China
- Prior art keywords
- tube
- blank
- pipe
- wall thickness
- tube blank
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 36
- 238000005452 bending Methods 0.000 claims abstract description 23
- 230000008859 change Effects 0.000 claims abstract description 7
- 238000000034 method Methods 0.000 claims description 29
- 239000007789 gas Substances 0.000 claims description 11
- 239000011261 inert gas Substances 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 4
- 238000001125 extrusion Methods 0.000 claims description 3
- 238000004804 winding Methods 0.000 claims description 2
- 230000003247 decreasing effect Effects 0.000 claims 5
- 230000007704 transition Effects 0.000 claims 2
- 230000007423 decrease Effects 0.000 description 15
- 230000008569 process Effects 0.000 description 15
- 239000000463 material Substances 0.000 description 6
- 238000003466 welding Methods 0.000 description 5
- 238000007789 sealing Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000005674 electromagnetic induction Effects 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 239000004575 stone Substances 0.000 description 2
- 241001465754 Metazoa Species 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000010009 beating Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000012761 high-performance material Substances 0.000 description 1
- 230000003116 impacting effect Effects 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000013049 sediment Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
- B21D35/002—Processes combined with methods covered by groups B21D1/00 - B21D31/00
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/033—Deforming tubular bodies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D31/00—Other methods for working sheet metal, metal tubes, metal profiles
- B21D31/06—Deforming sheet metal, tubes or profiles by sequential impacts, e.g. hammering, beating, peen forming
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D7/00—Bending rods, profiles, or tubes
- B21D7/06—Bending rods, profiles, or tubes in press brakes or between rams and anvils or abutments; Pliers with forming dies
Abstract
The invention relates to the technical field of forming of wheel housing bracket tube beams of automobiles, and provides a commercial automobile, a lightweight commercial wheel housing bracket tube beam thereof and a manufacturing method thereof. The manufacturing method of the lightweight commercial wheel house bracket tube beam comprises the following steps: s1: providing a tube blank; s2: reducing the wall thickness of the tube blank, sleeving the tube blank on a mandrel, rotating and feeding the tube blank, and simultaneously, symmetrically opening and closing the tube blank through 2-4 hammers at high frequency to reduce the outer diameter of the tube blank, wherein the outer diameter of the tube blank can be changed through changing the stroke of the hammers; meanwhile, the position of the mandrel is matched with the feeding stroke of the tube blank, so that continuous wall thickness change is realized, and the tube blank with a preset shape and wall thickness is obtained; s3: pre-bending the pipe blank with the preset shape and the wall thickness obtained in the step S2 to obtain a bent pipe blank; s4: performing hot gas expansion forming on the bent pipe blank obtained in the step S3 to obtain a pipe body of the light commercial wheel house bracket pipe beam; s5: and (4) installing a flange on the pipe body obtained in the step S4.
Description
Technical Field
The present invention relates to the field of forming technology for wheel house support tube beams for automobiles, and more particularly, to a method for manufacturing a lightweight commercial wheel house support tube beam, a lightweight commercial wheel house support tube beam manufactured by the manufacturing method, and a commercial vehicle including the lightweight commercial wheel house support tube beam.
Background
According to the requirements of GB7258-2017 'technical Condition for safety of motor vehicle's operation: the truck with total mass greater than 7500kg, the special working vehicle refitted from the truck chassis and the trailer with total mass greater than 3500kg should be provided with an anti-splash system, and all wheels of other motor vehicles should be provided with mud guards (also called wheel covers). The purpose of the device is to prevent sediment, broken stone and the like from impacting the chassis of the automobile, prevent components such as a pull rod, a ball head and the like from rusting and failing too early, prevent broken stone from splashing to hurt vehicles, roadside pedestrians and facilities in the adjacent running process, reduce the risk of people, animals, objects and the like being involved in the wheels of the running vehicles, play a role in guiding airflow, and reduce wind resistance in the running process of the vehicles.
The wheel cover is fixed on the wheel cover bracket, and the bracket comprises a bracket tube beam and an auxiliary bracket which is welded or hooped on the bracket tube beam and is used for fixing the wheel cover. The bracket tube beam comprises a flange and a tube body which are connected in a friction welding mode. The existing bracket tube beam is fixed with the frame through a flange and is in a cantilever beam working state, so that the stress working condition of the bracket tube beam is severe.
The related data show that if the weight of the whole automobile is reduced by 10%, the fuel efficiency can be improved by 6% -8%; every 100 kg of the weight of the whole automobile is reduced, the hundred kilometers of oil consumption can be reduced by 0.3-0.6 liter; the weight of the whole automobile is reduced by 1%, and the oil consumption can be reduced by 0.7%. Based on the requirements of environmental protection and energy saving, light weight has become a fundamental technical route for the automobile industry. Two groups of wheel cover brackets are required to be configured for each axle of a general commercial vehicle, and the average weight of each vehicle is about 40 kg, so that the commercial vehicle is technically upgraded in a light-weight manner, and has practical and urgent significance.
Taking heavy truck as an example, the existing bracket tubular beam generally adopts two structures of local bending and integral straight pipe, wherein the root of the tubular beam cantilever beam is provided with a diameter expanding scheme. The scheme adopts round tubes with equal diameter and equal wall thickness, and is formed by locally flaring of an elbow or a tube end, so that the choice of the tube blank material is limited, the yield cannot be too high, and the brand is Q345 at the highest; in order to meet the stress requirement of the cantilever beam root of the bracket tube beam, the diameter of a general tube blank is 50mm, the wall thickness is 4mm, the conventional process is also limited, when the local flaring of the tube end is about 60mm in diameter, the wall thickness is stretched and thinned, so that the local strength is reduced, and the wall thickness is the same along the whole process of the axis of the tube blank at the equal diameter part, so that the weight of parts is increased, the stress of the cantilever beam root is additionally increased under the vibration environment, and the fracture failure frequency of the bracket tube beam root is high. Through the innovative process method, the application of high-performance materials and the topological optimization of an equal-strength structure are realized, so that the bracket tube beam achieves the purposes of light weight and reliability improvement, and has a great demonstration effect on the light weight of automobile tube parts.
Disclosure of Invention
In order to solve or at least alleviate the above problems, the present invention provides a method of manufacturing a lightweight commercial wheel housing bracket tube beam. In addition, the invention also provides a light commercial wheel house bracket tube beam manufactured by the manufacturing method. The invention also provides a commercial vehicle comprising the lightweight commercial wheel house bracket tube beam.
The invention provides a manufacturing method of a lightweight commercial wheel house bracket tube beam, which comprises the following steps:
s1: providing a tube blank;
s2: reducing the wall thickness of the tube blank, sleeving the tube blank on a mandrel, rotating and feeding the tube blank, and simultaneously, symmetrically opening and closing the tube blank through 2-4 hammers at high frequency to reduce the outer diameter of the tube blank, wherein the outer diameter of the tube blank can be changed through changing the stroke of the hammers; meanwhile, the position of the mandrel is matched with the feeding stroke of the tube blank, so that continuous wall thickness change is realized, and the tube blank with a preset shape and wall thickness is obtained;
s3: pre-bending the pipe blank with the preset shape and the wall thickness obtained in the step S2 to obtain a bent pipe blank;
s4: performing hot gas expansion forming on the bent pipe blank obtained in the step S3 to obtain a pipe body of the light commercial wheel house bracket pipe beam;
s5: and (4) installing a flange on the pipe body obtained in the step S4.
In some embodiments, in step S2, after the outer diameter and wall thickness of the tube blank are changed and the mandrel is removed, the stepped tube blank is hit again by using 2-4 hammers to open and close symmetrically at high frequency, so as to obtain the reduced tube blank.
In some embodiments, step 3 uses a press bending method to obtain a tube blank for the bent tube.
In some embodiments, in step S3, the heated reduced diameter tube blank is placed into a lower die of a stamping die, and then clamped, and the reduced diameter tube blank is gradually formed under extrusion of an upper die, thereby obtaining a bent tube blank.
In some embodiments, step 3 uses a wrap-around method to obtain the tube blank of the elbow.
In some embodiments, in step 3, the heated reduced diameter tube blank is secured using a split and a clamp die, and the wheel die, split and clamp die are rotated together to bend the reduced diameter tube blank.
In some embodiments, guide ribs are provided on the wheel mold.
The invention also provides a light commercial wheel house support tube beam, which is manufactured by the manufacturing method of the light commercial wheel house support tube beam, the wheel house support tube beam comprises a tube body and a flange arranged at one end of the tube body, the tube body comprises a first tube part connected with the flange, a second tube part arranged far away from the flange and a third tube part connected with the first tube part and the second tube part, the first tube part and the second tube part are arranged in a staggered way, the third tube part is bent from the first tube part to the second tube part, the wall thickness of the first tube part gradually reduces and transits to the wall thickness of the third tube part, the wall thickness of the third tube part gradually reduces and transits to the wall thickness of the second tube part, the wall thickness of the second tube part gradually reduces from the starting end to the tail end of the second tube part, and the outer diameter of the third tube part gradually reduces from the connecting position with the first tube part to the connecting position with the second tube part.
In some embodiments, the wall thickness of the second tube portion decreases continuously and uniformly from its start to its end, or alternately decreases in a stepped fashion.
The invention also provides a commercial vehicle, which comprises the light commercial wheel house bracket tube beam.
Compared with the prior art, the invention has the beneficial effects that:
(1) The manufacturing method of the light commercial wheel housing bracket tube beam provided by the invention can provide an innovative light structure of the wheel housing bracket tube beam with the characteristics of variable cross section and variable wall thickness, can be suitable for the application of higher-grade high-strength steel, and can reduce the material consumption on the premise of ensuring the reliability.
(2) The manufacturing method of the light commercial wheel housing tube beam is used for manufacturing the wheel housing tube beam, so that the quality of the manufactured wheel housing tube beam is reduced, the light weight of the wheel housing tube beam is realized, and the light weight of an automobile is facilitated.
(3) The manufacturing method of the lightweight commercial wheel cover support tube beam is used for manufacturing the wheel cover support tube beam, so that the problems of fatigue fracture and the like of the wheel cover support tube beam can be solved, and the fatigue life of the wheel cover support tube beam can be prolonged.
Drawings
Fig. 1 shows a schematic view of the reduced wall thickness process of the manufacturing method of a lightweight commercial wheel house bracket tube beam according to the invention, in which the direction of movement of the tube blank is shown.
Fig. 2 shows a cross-sectional view of a stepped tube blank obtained by the reduced wall thickness process shown in fig. 1.
Fig. 3 shows a reduced diameter tube blank obtained by striking the step-shaped tube blank shown in fig. 2.
Fig. 4 shows a schematic diagram of a pre-bending process of a method of manufacturing a lightweight commercial wheel house support tube beam according to an embodiment of the present invention.
Fig. 5 shows a schematic diagram of a pre-bending process of a method of manufacturing a lightweight commercial wheel house support tube beam according to another embodiment of the present invention.
Fig. 6 shows a cross-sectional view of a wheel die used during the pre-bending process shown in fig. 5.
Fig. 7 shows a cross-sectional view of the bent pipe blank after the pre-bending process.
Fig. 8 shows a schematic view of a hot gas expansion forming process of a method of manufacturing a lightweight commercial wheel house support tube beam according to the present invention.
Fig. 9 illustrates a perspective view of a lightweight commercial wheel house support tube beam in accordance with an embodiment of the present invention.
Fig. 10 shows a reduced diameter tube blank obtained in the process of manufacturing the lightweight commercial wheel house carrier tube beam shown in fig. 9.
Fig. 11 shows a tube blank of the elbow pipe obtained in the process of manufacturing the lightweight commercial wheel house carrier tube beam shown in fig. 9.
Fig. 12 shows a cross-sectional view of the body of the lightweight commercial wheel house support tube beam of fig. 9.
Fig. 13 illustrates the bending moment of the lightweight commercial wheel housing support tube beam of fig. 9 when subjected to downward forces.
Reference numerals illustrate: 1-hammer head; 2-a mandrel; 3-electromagnetic induction coils; 4-pipe blank; 41-step-shaped tube blank; 42-reducing tube blank; 43-bending pipe blank; 431-recess; 5-lower die; 6-upper die; 7-hot air expansion forming die; 71-hot air expansion forming die upper die; 72-hot air expansion forming die lower die; 8-an oil cylinder; 9-sealing the push head; 10-trachea; 11-air source; 12-wheel mold; 121-a guide rib; 13-tiling; 14-clamping the mold; 15-guiding the mold; 16-crease-resist die; 17-wheel cover bracket tube beams; 171-tube body; 1711-a first tube portion; 1713-a second tube portion; 1712-a third tube portion; 172-flange.
Detailed Description
The invention will be further described with reference to the drawings and the specific embodiments.
It should be noted that the following detailed description is illustrative and is intended to provide further explanation of the invention. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present invention. As used herein, the singular is also intended to include the plural unless the context clearly indicates otherwise, and furthermore, it is to be understood that the terms "comprises" and/or "comprising" when used in this specification are taken to specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof.
In the present invention, terms such as "upper", "lower", "left", "right", "front", "rear", "vertical", "horizontal", "side", "bottom", etc. refer to an orientation or a positional relationship based on that shown in the drawings, and are merely relational terms, which are used for convenience in describing structural relationships of various components or elements of the present invention, and do not denote any one of the components or elements of the present invention, and are not to be construed as limiting the present invention.
In the present invention, terms such as "fixedly attached," "connected," "coupled," and the like are to be construed broadly and refer to either a fixed connection or an integral or removable connection; can be directly connected or indirectly connected through an intermediate medium. The specific meaning of the terms in the present invention can be determined according to circumstances by a person skilled in the relevant art or the art, and is not to be construed as limiting the present invention.
Example 1
Fig. 1, 4 and 8 show a method for manufacturing a lightweight commercial wheel house bracket tube beam according to embodiment 1 of the present invention. The manufacturing method of the lightweight commercial wheel house bracket tube beam in the embodiment comprises the following steps:
s1: a tube blank 4 is provided. The corresponding tube blank is selected according to the required size of the wheel cover bracket tube beam.
S2: reducing the wall thickness of the tube blank 4, sleeving the tube blank 4 on the mandrel 2 for rotary feeding, and simultaneously, beating the tube blank 4 through a plurality of hammers 1 in a high-frequency opening and closing manner so as to reduce the outer diameter of the tube blank 4, wherein the outer diameter of the tube blank 4 can be changed by changing the stroke of the hammers 1; meanwhile, the position of the mandrel 2 is matched with the feeding stroke of the tube blank 4, so that continuous non-uniform thickness wall thickness change is realized, and the tube blank with the preset shape and wall thickness is obtained. In step S2, the blank pipe 4 is heated by the electromagnetic induction coil 3, so that the yield strength of the blank pipe 4 is reduced and the elongation is increased. Preferably, the tube blank 4 is heated to 800-950 ℃, sleeved on the mandrel 2 and fed in a rotating way, and simultaneously the tube blank is symmetrically opened and closed at high frequency through 2-4 symmetrical hammers 1, and the outer diameter of the tube blank 4 can be changed by changing the stroke of the hammers 1; meanwhile, the position of the mandrel 2 is matched with the feeding stroke of the tube blank 4, so that continuous non-uniform thickness wall thickness change is realized, and the tube blank with the preset shape and wall thickness is obtained. In this embodiment, the taper of the mandrel 2 facilitates material flow in the direction of extension and intermittent cooling. As shown in fig. 2, after the outer diameter and wall thickness of the tube blank 4 are changed, a stepped tube blank 41 is obtained, and the thickness distribution of the stepped tube blank 41 can be adjusted as needed. As shown in fig. 3, after the mandrel 2 is removed, the stepped tube blank 41 is opened and closed again by the plurality of hammers 1 at high frequency, and the reduced tube blank 42 is obtained. It is also preferable that in step S2, after the outer diameter and the wall thickness of the tube blank 4 are changed, a tube blank 41 having a gradually changed or stepped wall thickness is obtained, and then after the mandrel 2 is removed, the stepped tube blank 41 is hit again by using 2 to 4 hammers 1 with cavities, and the reduced tube blanks 42 having various reducing shapes are obtained by symmetrical high-frequency opening and closing.
S3: the tube blank of the predetermined shape and wall thickness obtained in step S2 is pre-bent to obtain a bent tube blank 43. In the present embodiment, the bent pipe blank 43 is obtained by press bending. Specifically, the heated reduced diameter tube blank 42 is placed in the lower die 5 of the press die, and then the dies are clamped. Under the combined extrusion of the upper die 6 and the lower die 5, the reduced diameter tube blank 42 is gradually formed to obtain the elbow tube blank 43. It is conceivable that this step may be omitted for a straight pipe-shaped tubular beam.
S4: and (3) performing hot gas expansion forming on the bent pipe blank 43 obtained in the step (S3) to obtain a pipe body of the lightweight commercial wheel house bracket pipe beam. Preferably, the bent pipe blank 43 is heated in a heating furnace, so that the yield strength of the bent pipe blank 43 is reduced and the elongation is increased. After the heated pipe blank 43 is put into the hot gas expansion forming die 7, the upper die 71 of the hot gas expansion forming die and the lower die 72 of the hot gas expansion forming die are closed, and the oil cylinder 8 pushes the sealing push head 9 to move forwards to seal the pipe orifice of the pipe blank 43. The air source 11 supplies high-pressure inert gas into the pipe blank 43 through the air pipe 10 and the sealing push head 9, so that the pipe blank 43 is expanded and deformed and is attached to the inner side of the hot air expansion forming die 7. Specifically, the bent pipe blank 43 is heated and then placed into a hot gas expansion forming die, the die is closed, pipe orifices at two ends of the bent pipe blank 43 are sealed, then high-pressure inert gas is conveyed into the bent pipe blank 43 to enable the bent pipe blank to expand and deform, the bent pipe blank is attached to the inner side of the hot gas expansion forming die, the pipe body is subjected to finish machining, and various profile structures, such as gradual change of diameters of bent parts, and the pipe body is formed and locally connected with a convex concave surface and the like, so that the pipe body of the light commercial wheel cover support pipe beam is obtained.
Further, the manufacturing method of the lightweight commercial wheel house bracket tube beam of the embodiment further includes the steps of:
s5: and (3) welding the flange on the pipe body obtained in the step S4 in a welding mode to obtain the final lightweight commercial wheel housing bracket pipe beam. Preferably, the flange is connected to the pipe body by friction welding.
Example 2
Fig. 1, 5 and 8 show a method for manufacturing a lightweight commercial wheel house bracket tube beam according to embodiment 2 of the present invention. The method for manufacturing the lightweight commercial wheel house support tube beam of example 2 employs a pre-bending tube method different from the method for manufacturing the lightweight commercial wheel house support tube beam of example 1.
In the present embodiment, the bent pipe blank 43 is obtained by winding. Specifically, the heated reduced diameter tube blank 42 is fixed by the split blocks 13 and the clamping dies 14. The wheel die 12, the splice 13 and the clamping die 14 rotate together to bend the reduced diameter tube blank 42, and the angle of the bent tube can be changed by changing the rotation angle of the wheel die 12. The guide die 15 is used for guiding the reducing pipe blank 42, the crease-resist die 16 can reduce the occurrence of inner creasing of the pipe blank 43 during bending, and the guiding ribs 121 (shown in fig. 6) are provided on the wheel die 12, so that creasing of the pipe blank 43 can be effectively prevented. Preferably, the guide rib 121 guides the excess material inside the bent portion of the tube blank to form an axial recess, so that the film is easily stuck during the bulging. As shown in fig. 6 and 7, the cross section of the elbow pipe blank 43 is changed by the guide rib 121, and the elbow pipe blank 43 is formed with a concave portion 431 recessed inward of the elbow pipe blank 43 at a position corresponding to the guide rib 121, which effectively prevents wrinkling of the inside of the elbow pipe blank 43 during pre-bending.
Example 3
Fig. 9 shows a perspective view of a lightweight commercial wheel house support tube beam made by the method of manufacturing a lightweight commercial wheel house support tube beam according to the present invention. The wheel housing bracket tube beam 17 includes a tube body 171 and a flange 172 mounted at one end of the tube body 171. Preferably, flange 172 is friction welded to tube 171. In this embodiment, the tube 171 includes a first tube 1711 connected to the flange 172, a second tube 1713 disposed away from the flange 172, and a third tube 1712 connecting the first tube 1711 and the second tube 1713. The first tube portion 1711 is offset from the second tube portion 1713, preferably parallel offset, wherein the third tube portion 1712 is bent from the first tube portion 1711 to the second tube portion 1713.
In this embodiment, flange 172 is made of Q345 and tube 171 is made of Q550. As shown in fig. 9, the specifications of each part of the tube body 171 of the wheel cover bracket tube beam 17 are: first tube portion 1711 has a specification of 1 :60 x 3.5 (in mm); the starting portion of the second tube portion 1713 has a specification of 2 :50 x 2.5 (in mm), the end portion of the second tube portion 1713 has a gauge of # 3 : 50.1.8-2 (in mm). Preferably, the wall thickness of the first tube portion 1711 gradually decreases to the wall thickness of the third tube portion 1712, the wall thickness of the third tube portion 1712 gradually decreases to the wall thickness of the second tube portion 1713, the wall thickness of the second tube portion 1713 gradually decreases from the start end to the end, and the outer diameter of the third tube portion 1712 gradually decreases from the connection with the first tube portion 1711 to the connection with the second tube portion 1713.
The wheel house support tube beam 17 is manufactured by the manufacturing method of the lightweight commercial wheel house support tube beam of the present invention. Providing a tube blank made of Q550 with a specification phi 4 :57 x 4.0 (in mm). The tube blank is sleeved on a mandrel to be rotationally fed, and an electromagnetic induction coil heats the tube blank to 850-950 ℃.The hammers are opened and closed at high frequency to strike the tube blank, so that the outer diameter of the tube blank is reduced; the position of the mandrel is matched with the feeding stroke, so that continuous wall thickness change is realized, and the stepped tube blank is obtained. After the mandrel is removed, the stepped tube blank is opened and closed again by a plurality of hammers at high frequency, and the reduced tube blank 42 is obtained. In this process, the dimensions of the various portions of the reduced diameter tube blank 42 are as shown in fig. 10. Specifically, the reduced diameter tube stock 42 has a gauge Φ at a position corresponding to the first tube portion 1711 4 :57 x 4.0 (in mm); the specification at the position corresponding to the start end of the second tube portion 1713 is phi 5 :50 x 2.6 (in mm), the gauge at the location corresponding to the end of the second tube portion 1713 is phi 6 :50 x 2 (in mm) the wall thickness of this portion gradually decreases; further, the wall thickness of the intermediate portion of the diameter-reduced tube blank 42 between the position corresponding to the first tube portion 1711 and the position corresponding to the start end of the second tube portion 1713 is gradually reduced, and the outer diameter is gradually reduced.
Then, the reduced diameter tube blank 42 is heated to 650-750 ℃ by a heating furnace, and the heated reduced diameter tube blank 42 is fixed by splicing and clamping dies. The wheel die, the segments and the clamping die are rotated together to bend the reduced diameter tube blank to obtain a bent tube blank 43, as shown in fig. 11. Specifically, the bent pipe blank 43 has a specification of Φ at a position corresponding to the first pipe portion 1711 4 :57 x 4.0 (in mm); the specification at the position corresponding to the start end of the second tube portion 1713 is phi 5 :50 x 2.6 (in mm), the gauge at the location corresponding to the end of the second tube portion 1713 is phi 6 :50 x 2 (in mm) the wall thickness of this portion gradually decreases; further, the wall thickness of the reduced diameter tube stock 42 at the position corresponding to the third tube portion 1712 was 3mm, and the outer diameter thereof was gradually reduced.
Heating the bent pipe blank 43 to 900-1000 ℃, putting the bent pipe blank into a hot gas expansion forming die to be matched, and sealing two ends. The air source delivers high-pressure inert gas (air pressure is 35-50MPa, inflation time is 20-30S, and dwell time is 20-30S) into the pipe blank 43 through one end of the air source, so that the pipe blank 43 is expanded and deformed, and is attached to a die to form a pipe body 171 (shown in FIG. 12). Specifically, the wall thickness of the first tube portion 1711 gradually decreases to the wall thickness of the third tube portion 1712, the wall thickness of the third tube portion 1712 gradually decreases to the wall thickness of the second tube portion 1713, the wall thickness of the second tube portion 1713 gradually decreases from the start end to the end, and the outer diameter of the third tube portion 1712 gradually decreases from the first tube portion 1711 to the second tube portion 1713. Preferably, the wall thickness at the first tube portion 1711 is 3.5mm and the outer diameter is 60mm. It is also preferred that the wall thickness at the third tube portion 1712 be 3mm, with an outer diameter that tapers from the end of the first tube portion 1711 to the beginning of the second tube portion 1713. More preferably, the second tube portion 1713 has a beginning wall thickness of 2.6mm and an end wall thickness of 2mm and an outer diameter of 50mm. It is also preferred that the wall thickness of the second tube portion 1713 decreases continuously and evenly from its start to its end, or alternately decreases in a stepped fashion.
Finally, the flange 172 is welded to the tube 171 by welding to obtain the final lightweight commercial wheel housing bracket tube beam. Preferably, flange 172 is friction welded to tube 171.
The lightweight commercial wheel house support tube beam obtained above was tested. As shown in fig. 13, the joint of the fixing flange 172 and the pipe 171 is spaced apart from the pipelAt the location of (2) applying a downward forceFThe bending moment to which the tube body 171 is subjected can be obtained. As can be seen, the bending moment at the junction of flange 172 and tube 171 is the greatest and has a value ofFl. The moment of inertia of the hollow circle is:the bending-resistant section coefficients are as follows: />The method comprises the steps of carrying out a first treatment on the surface of the Wherein D is the outer diameter of the hollow circle, and D is the inner diameter of the hollow circle. As can be seen from fig. 13, the wall thickness of the pipe body gradually decreases from left to right, so that the moment of inertia and the bending resistance cross-section coefficient at the joint of the flange and the pipe body are the largest, and the moment of inertia and the bending resistance cross-section coefficient at the end of the pipe body are the smallest. The wheel cover bracket tube beam can be judged by combining the bending moment born by the tube body, the equal strength design is realized through the variable cross section and unequal wall thickness, the materials are effectively utilized, and the equal wall thickness over design is avoided.
Example 4
The invention also provides a commercial vehicle, which comprises the wheel cover bracket tube beam, wherein the wheel cover and the mud guard of the commercial vehicle are installed through the wheel cover bracket tube beam.
Compared with the prior art, the wheel cover bracket tube beam provided by the invention has the advantages of reduced quality, obvious light weight effect and contribution to light weight of automobiles; the design of equal strength is realized through variable cross section and unequal wall thickness, materials are effectively utilized, and the over design of equal wall thickness is avoided.
The above description is only of the preferred embodiments of the present invention and is not intended to limit the present invention, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (8)
1. A method of manufacturing a lightweight commercial wheel housing support tube beam, the manufactured wheel housing support tube beam comprising a tube body and a flange mounted at one end of the tube body, the tube body comprising a first tube portion connected to the flange, a second tube portion disposed away from the flange, and a third tube portion connecting the first tube portion and the second tube portion, the method comprising the steps of:
s1: providing a tube blank;
s2: reducing the wall thickness of the tube blank, sleeving the tube blank on a mandrel, rotating and feeding the tube blank, and simultaneously, symmetrically opening and closing the tube blank through 2-4 hammers at high frequency to reduce the outer diameter of the tube blank, wherein the outer diameter of the tube blank can be changed through changing the stroke of the hammers; meanwhile, the position of the mandrel is matched with the feeding stroke of the tube blank, so that the continuous wall thickness change of the whole tube blank is realized, a stepped tube blank with a preset shape and a preset wall thickness is obtained, after the wall thickness of the outer diameter of the tube blank is changed and the mandrel is removed, the stepped tube blank is hit again by utilizing 2-4 hammers in a high-frequency symmetrical opening and closing manner, a reduced tube blank is obtained, the wall thickness of the middle part of the position of the reduced tube blank corresponding to the first tube part and the position of the starting end of the second tube part is gradually reduced, and the outer diameter is gradually reduced;
s3: pre-bending the stepped tube blank with the preset shape and the preset wall thickness obtained in the step S2 to obtain a tube blank with the bent tube, wherein the first tube part and the second tube part are staggered, and the third tube part is bent from the first tube part to the second tube part;
s4: performing hot gas expansion forming on the pipe blank of the bent pipe obtained in the step S3, heating the pipe blank of the bent pipe to 900-1000 ℃, putting the pipe blank of the bent pipe into a hot gas expansion forming die, closing the two ends of the pipe blank, conveying high-pressure inert gas into the pipe blank of the bent pipe by an air source through one end of the pipe blank, wherein the air pressure of the high-pressure inert gas is 35-50MPa, the air charging time is 20-30S, the pressure maintaining time is 20-30S, expanding and deforming the pipe blank of the bent pipe, attaching the pipe blank to the die, gradually reducing the outer diameter of a third pipe part from the tail end of the first pipe part to the starting end of a second pipe part, and obtaining the pipe body of the light commercial wheel cover bracket pipe beam, wherein the wall thickness of the second pipe part is continuously and uniformly gradually reduced from the starting end to the tail end of the second pipe part, or alternately reduced in a step form;
s5: and (4) installing a flange on the pipe body obtained in the step S4.
2. The method for manufacturing a lightweight commercial wheel house bracket tube beam according to claim 1, wherein step 3 is a bending tube blank obtained by press bending.
3. The method for manufacturing a lightweight commercial wheel house bracket tubular beam according to claim 2, wherein in step S3, the heated reduced diameter tube blank is placed in a lower die of a press die, and then closed, and the reduced diameter tube blank is gradually formed under the extrusion of an upper die, to obtain the bent tube blank.
4. The method for manufacturing a lightweight commercial wheel house bracket tube beam according to claim 1, wherein step 3 is a tube blank of an elbow tube obtained by winding.
5. The method of manufacturing a lightweight commercial wheel house bracket tubular beam according to claim 4, wherein in step 3, the heated reduced diameter tubular blank is fixed by a split block and a clamp die, and the wheel die, the split block and the clamp die are rotated together to bend the reduced diameter tubular blank.
6. The method of manufacturing a lightweight commercial wheel house frame tube beam according to claim 5, wherein guide ribs are provided on the wheel mold.
7. A lightweight commercial wheel house carrier tubular beam made by the method of manufacturing a lightweight commercial wheel house carrier tubular beam as claimed in any one of claims 1 to 6, the wheel house carrier tubular beam comprising a tubular body and a flange mounted at one end of the tubular body, the tubular body comprising a first tubular portion connected to the flange, a second tubular portion disposed remote from the flange, and a third tubular portion connecting the first and second tubular portions, the wall thickness of the first tubular portion gradually decreasing to transition to the wall thickness of the third tubular portion, the wall thickness of the third tubular portion gradually decreasing to transition to the wall thickness of the second tubular portion, the wall thickness of the second tubular portion continuously decreasing evenly from its starting end to its ending end, or alternately decreasing in a stepped fashion, and the outer diameter of the third tubular portion gradually decreasing from the connection with the first tubular portion to the connection with the second tubular portion.
8. A commercial vehicle comprising the lightweight commercial wheel housing support tube beam of claim 7.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310736009.8A CN116475305B (en) | 2023-06-21 | 2023-06-21 | Commercial vehicle and light commercial wheel house bracket tube beam and manufacturing method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310736009.8A CN116475305B (en) | 2023-06-21 | 2023-06-21 | Commercial vehicle and light commercial wheel house bracket tube beam and manufacturing method thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN116475305A CN116475305A (en) | 2023-07-25 |
| CN116475305B true CN116475305B (en) | 2023-10-24 |
Family
ID=87212231
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202310736009.8A Active CN116475305B (en) | 2023-06-21 | 2023-06-21 | Commercial vehicle and light commercial wheel house bracket tube beam and manufacturing method thereof |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN116475305B (en) |
Citations (18)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1198575A (en) * | 1997-02-12 | 1998-11-11 | 齐赫考都博公司 | Process for producing guide tube of nuclear reactor fuel assembly, mandrel for forming the guide tube, and guide tube obtained |
| JP2004009067A (en) * | 2002-06-04 | 2004-01-15 | Nippon Steel Corp | Front-side member for car |
| CN1478620A (en) * | 2002-07-22 | 2004-03-03 | ��ʽ�����װ | Method for manufacturing pipeline system with connecting part |
| CN101879565A (en) * | 2010-06-04 | 2010-11-10 | 衡阳连续运输机械有限公司 | Manufacturing method of welded steel pipe-free integrally formed automobile transaxle housing |
| CN102015377A (en) * | 2008-04-08 | 2011-04-13 | 昭和电工株式会社 | Bumper reinforcement for vehicles |
| CN102240892A (en) * | 2011-05-24 | 2011-11-16 | 中国第一汽车集团公司 | Method for forming hollow front shaft |
| CN103894476A (en) * | 2014-03-26 | 2014-07-02 | 吉林大学 | Overall thermal expansion manufacturing method for heavy-duty car drive axle housing |
| CN105598265A (en) * | 2015-12-21 | 2016-05-25 | 哈尔滨奔马科技有限公司 | Overall forming method of small-relative-bending-radius and large-diameter-thickness-ratio thin-walled bent pipe fitting |
| CN106216481A (en) * | 2016-09-14 | 2016-12-14 | 哈尔滨工业大学 | A kind of big section difference odd-shaped cross section pipe fitting swelling pressure combined shaping method |
| CN107520328A (en) * | 2017-06-21 | 2017-12-29 | 保隆(安徽)汽车配件有限公司 | A kind of forming elbow method and bend pipe mould |
| CN208503701U (en) * | 2018-05-30 | 2019-02-15 | 杭州温格科技有限公司 | Splitter |
| CN209870543U (en) * | 2019-04-24 | 2019-12-31 | 青岛世冠装备科技有限公司 | Bending axis instrument panel tubular beam |
| CN110788179A (en) * | 2019-11-22 | 2020-02-14 | 保隆(安徽)汽车配件有限公司 | Forming method of oval bent pipe with complicated cross-section circumference change and pipe bending device |
| DE102020113950A1 (en) * | 2020-05-25 | 2021-11-25 | Endress+Hauser Flowtec Ag | Welding neck flange for connecting a measuring tube of a flow measuring device and flow measuring device with a welding neck flange |
| CN215657209U (en) * | 2021-09-06 | 2022-01-28 | 安徽博天汽车零部件有限公司 | Pipe bending device for machining pipe beam of automobile instrument board cross beam |
| CN114713711A (en) * | 2021-12-21 | 2022-07-08 | 倍力汽车轻量化科技(潍坊)有限公司 | Pipe blank reducing method for expansion-compression molding process of drive axle housing |
| CN114713700A (en) * | 2021-12-21 | 2022-07-08 | 倍力汽车轻量化科技(潍坊)有限公司 | Hot-air-expansion integrated forming method for lightweight drive axle housing |
| CN115090774A (en) * | 2022-06-21 | 2022-09-23 | 广东轻量科技发展有限责任公司 | Pipe reducing mold with equal wall thickness and pipe reducing process |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US8468698B2 (en) * | 2009-07-15 | 2013-06-25 | Honda Motor Co., Ltd. | Spinning method |
-
2023
- 2023-06-21 CN CN202310736009.8A patent/CN116475305B/en active Active
Patent Citations (18)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1198575A (en) * | 1997-02-12 | 1998-11-11 | 齐赫考都博公司 | Process for producing guide tube of nuclear reactor fuel assembly, mandrel for forming the guide tube, and guide tube obtained |
| JP2004009067A (en) * | 2002-06-04 | 2004-01-15 | Nippon Steel Corp | Front-side member for car |
| CN1478620A (en) * | 2002-07-22 | 2004-03-03 | ��ʽ�����װ | Method for manufacturing pipeline system with connecting part |
| CN102015377A (en) * | 2008-04-08 | 2011-04-13 | 昭和电工株式会社 | Bumper reinforcement for vehicles |
| CN101879565A (en) * | 2010-06-04 | 2010-11-10 | 衡阳连续运输机械有限公司 | Manufacturing method of welded steel pipe-free integrally formed automobile transaxle housing |
| CN102240892A (en) * | 2011-05-24 | 2011-11-16 | 中国第一汽车集团公司 | Method for forming hollow front shaft |
| CN103894476A (en) * | 2014-03-26 | 2014-07-02 | 吉林大学 | Overall thermal expansion manufacturing method for heavy-duty car drive axle housing |
| CN105598265A (en) * | 2015-12-21 | 2016-05-25 | 哈尔滨奔马科技有限公司 | Overall forming method of small-relative-bending-radius and large-diameter-thickness-ratio thin-walled bent pipe fitting |
| CN106216481A (en) * | 2016-09-14 | 2016-12-14 | 哈尔滨工业大学 | A kind of big section difference odd-shaped cross section pipe fitting swelling pressure combined shaping method |
| CN107520328A (en) * | 2017-06-21 | 2017-12-29 | 保隆(安徽)汽车配件有限公司 | A kind of forming elbow method and bend pipe mould |
| CN208503701U (en) * | 2018-05-30 | 2019-02-15 | 杭州温格科技有限公司 | Splitter |
| CN209870543U (en) * | 2019-04-24 | 2019-12-31 | 青岛世冠装备科技有限公司 | Bending axis instrument panel tubular beam |
| CN110788179A (en) * | 2019-11-22 | 2020-02-14 | 保隆(安徽)汽车配件有限公司 | Forming method of oval bent pipe with complicated cross-section circumference change and pipe bending device |
| DE102020113950A1 (en) * | 2020-05-25 | 2021-11-25 | Endress+Hauser Flowtec Ag | Welding neck flange for connecting a measuring tube of a flow measuring device and flow measuring device with a welding neck flange |
| CN215657209U (en) * | 2021-09-06 | 2022-01-28 | 安徽博天汽车零部件有限公司 | Pipe bending device for machining pipe beam of automobile instrument board cross beam |
| CN114713711A (en) * | 2021-12-21 | 2022-07-08 | 倍力汽车轻量化科技(潍坊)有限公司 | Pipe blank reducing method for expansion-compression molding process of drive axle housing |
| CN114713700A (en) * | 2021-12-21 | 2022-07-08 | 倍力汽车轻量化科技(潍坊)有限公司 | Hot-air-expansion integrated forming method for lightweight drive axle housing |
| CN115090774A (en) * | 2022-06-21 | 2022-09-23 | 广东轻量科技发展有限责任公司 | Pipe reducing mold with equal wall thickness and pipe reducing process |
Also Published As
| Publication number | Publication date |
|---|---|
| CN116475305A (en) | 2023-07-25 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CA2526117C (en) | Tubular axle housing assembly with varying wall thickness | |
| RU2126306C1 (en) | Ladder frame unit for motor type transport vehicle | |
| US8616570B2 (en) | Method for producing a control arm, and a control arm | |
| US8833127B2 (en) | Hollow member and an apparatus and method for its manufacture | |
| RU2693275C2 (en) | Extruded pipe from aluminium alloy and method of vehicle body component molding | |
| CN102225491A (en) | Method and device for forming metal reducer pipe based on laser shock wave technology | |
| US8220811B2 (en) | Arm material and a method for its manufacture | |
| US20140068945A1 (en) | Method Of Producing Tailored Tubes | |
| CN116475305B (en) | Commercial vehicle and light commercial wheel house bracket tube beam and manufacturing method thereof | |
| JP3863099B2 (en) | Bumper, stay, and electromagnetic forming method for forming flange on stay | |
| US6941786B1 (en) | Component specific tube blanks for hydroforming body structure components | |
| US6807837B1 (en) | Method and apparatus for producing variable wall thickness tubes and hollow shafts | |
| CN114713711A (en) | Pipe blank reducing method for expansion-compression molding process of drive axle housing | |
| CN114713700B (en) | Method for integrally forming lightweight driving axle housing through hot air expansion | |
| CN114802477A (en) | Lightweight fender bracket and mounting structure and manufacturing method thereof | |
| US7028404B1 (en) | Apparatus and method of manufacturing a vehicle frame assembly | |
| US20050097935A1 (en) | Method for shaping a bent single- or multiple-chamber hollow profile internal high pressure | |
| CN109803877B (en) | Instrument panel beam, bracket set and instrument panel beam joint body | |
| US6454990B1 (en) | Mechanism for supporting a workpiece during a heat treatment process | |
| CN115365318A (en) | Value flow method for forming vehicle structural stringers | |
| CN116834833A (en) | New energy large-bending side beam rear auxiliary frame | |
| CN114713700A (en) | Hot-air-expansion integrated forming method for lightweight drive axle housing |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |